Geared turbofan with integral front support and carrier

ABSTRACT

A gas turbine engine includes a nacelle, and a bypass flow path in a bypass duct within the nacelle of the turbofan engine. A fan section includes a fan with fan blades. The fan section drives air along the bypass flow path. A fan shaft drives a fan that has fan blades and the fan rotates about a central longitudinal axis of the turbofan engine. A speed reduction device includes an epicyclic gear system. A turbine section is connected to the fan section through the speed reduction device and the turbine section rotates about the central longitudinal axis. A first fan bearing for supporting rotation of the fan hub is located axially forward of the speed reduction device. A second fan bearing for supporting rotation of the fan hub is located axially aft of the speed reduction device. A first outer race of the first fan bearing is fixed relative to the fan hub.

CROSS-REFERENCE TO RELATED APPLICATIONS

This disclosure is a continuation of U.S. application Ser. No.14/633,244 filed on Feb. 27, 2015, which claims priority to U.S.Provisional Application No. 61/949,331, which was filed on Mar. 7, 2014and is incorporated herein by reference.

BACKGROUND

A gas turbine engine typically includes a fan section, a compressorsection, a combustor section and a turbine section. Air entering thecompressor section is compressed and delivered into the combustionsection where it is mixed with fuel and ignited to generate ahigh-energy exhaust gas flow. The high-energy exhaust gas flow expandsthrough the turbine section to drive the compressor and the fan section.The compressor section typically includes low and high pressurecompressors, and the turbine section includes low and high pressureturbines.

A speed reduction device such as an epicyclical gear assembly may beutilized to drive the fan section such that the fan section may rotateat a speed different than the turbine section so as to increase theoverall propulsive efficiency of the engine. In such enginearchitectures, a shaft driven by one of the turbine sections provides aninput to the epicyclical gear assembly that drives the fan section at areduced speed such that both the turbine section and the fan section canrotate at closer to optimal speeds.

The epicyclical gear assembly includes bearings that support rotation ofgears. Loads incurred during operation can disrupt a desired relativealignment between gears and therefore the gear assembly may be supportedon structures designed to accommodate such loads.

Although geared architectures improve propulsive efficiency, theypresent different challenges that can reduce any efficiency gains.Accordingly, turbine engine manufacturers continue to seek furtherimprovements to engine performance including improvements to thermal,transfer and propulsive efficiencies.

SUMMARY

In one exemplary embodiment, a gas turbine engine includes a nacelle,and a bypass flow path in a bypass duct within the nacelle of theturbofan engine. A fan section includes a fan with fan blades. The fansection drives air along the bypass flow path. A fan shaft drives a fanthat has fan blades and the fan rotates about a central longitudinalaxis of the turbofan engine. A speed reduction device includes anepicyclic gear system. A turbine section is connected to the fan sectionthrough the speed reduction device and the turbine section rotates aboutthe central longitudinal axis. A first fan bearing for supportingrotation of the fan hub is located axially forward of the speedreduction device. A second fan bearing for supporting rotation of thefan hub is located axially aft of the speed reduction device. A firstouter race of the first fan bearing is fixed relative to the fan hub.

In a further embodiment of any of the above, the second fan bearingincludes an outer race. The outer race of the first fan bearing and theouter race of the second fan bearing are fixed relative to the fan huband rotate with the fan hub in the same direction.

In a further embodiment of any of the above, an inner race of the firstfan bearing is fixed from rotation relative to an engine staticstructure. An inner race of the second fan bearing is fixed fromrotation relative to the engine static structure.

In a further embodiment of any of the above, the epicyclic gear systemincludes a sun gear, star gears, a ring gear mechanically attached tothe fan section, and a carrier. The carrier is fixed from rotationrelative to the engine static structure.

In a further embodiment of any of the above, the first fan bearing andthe second fan bearing include at least one of roller bearings, ballbearings, or tapered bearings. Each of the star gears include a stargear bearing.

In a further embodiment of any of the above, the carrier includesmultiple flexible posts for mounting each of the star gears and the stargear bearing.

In a further embodiment of any of the above, the first fan bearing is atleast partially axially aligned with a fan blade of the fan section.

In a further embodiment of any of the above, a carrier is fixed fromrotation relative to an engine static structure without a staticflexible mount.

In a further embodiment of any of the above, an inner race of the firstfan bearing is fixed from rotation relative to a carrier. The carrier isfixed from rotation relative to an engine static structure.

In a further embodiment of any of the above, a high pressure compressorwith a compression ratio of at least 20:1 and a fan bypass ratio greaterthan 10.

In a further embodiment of any of the above, a compressor section isconfigured to rotate with the fan section. The compressor sectionincludes a five stage low pressure compressor with a compression ratioof at least 2:1.

In a further embodiment of any of the above, a rotating compartment wallis configured to rotate with the compressor section and form a seal withan engine static structure.

In a further embodiment of any of the above, the speed reduction deviceis located radially inward from a first compressor. The speed reductiondevice is axially aligned with the first compressor.

In another exemplary embodiment, a fan drive gear module includes a sungear and a multitude of intermediate gears surrounding the sun gear. Acarrier supports the multitude of intermediate gears. The carrier isconfigured to support a fan hub with a first fan bearing located on afirst side of the carrier and a second fan bearing located on a secondopposite side of the carrier. The carrier is configured to be fixed fromrotation relative to an engine static structure without a staticflexible mount. An outer race of the first fan bearing and an outer raceof the second fan bearing are fixed relative to the fan hub and rotatewith the fan hub in the same direction.

In a further embodiment of any of the above, an inner race of the firstfan bearing is fixed from rotation relative to a carrier. The carrier isfixed from rotation relative to the engine static structure.

In a further embodiment of any of the above, each of the multitude ofintermediate gears include an intermediate gear bearing. The carrierincludes multiple flexible posts for mounting each of the multitude ofintermediate gears and the intermediate gear bearing.

In a further embodiment of any of the above, a ring gear is fixedrelative to the fan hub and the first fan bearing and the second fanbearing include at least one of roller bearings, ball bearings, ortapered bearings.

In another exemplary embodiment, a method of designing a gas turbineengine includes coupling a speed reduction device between a fan hub anda low pressure turbine drive shaft. A first fan bearing is positionedaxially forward of the speed reduction device. An outer race of thefirst fan bearing is fixed relative to the fan hub and rotates with thefan hub relative to an engine static structure. A second fan bearing ispositioned axially aft of the speed reduction device. An outer race ofthe second fan bearing is fixed relative to the fan hub and rotates inthe same rotational direction as the outer race of the first fanbearing.

In a further embodiment of any of the above, an inner race of the firstfan bearing and an inner race of the second fan bearing is positionedfixed to a carrier and fixed from rotation relative to the engine staticstructure.

In a further embodiment of any of the above, a ring gear of the speedreduction device relative to the fan hub is fixed to allow the ring gearto rotate with the fan hub. The first fan bearing and the second fanbearing include at least one of roller bearings, ball bearings, ortapered bearings.

The various features and advantages of this disclosure will becomeapparent to those skilled in the art from the following detaileddescription. The drawings that accompany the detailed description can bebriefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an example gas turbine engine.

FIG. 2 is a schematic view of an example geared architecture.

FIG. 3 is a schematic view of another example geared architecture.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates a gas turbine engine 20. The gasturbine engine 20 is disclosed herein as a two-spool turbofan thatgenerally incorporates a fan section 22, a compressor section 24, acombustor section 26 and a turbine section 28. Alternative engines mightinclude an augmentor section (not shown) among other systems orfeatures. The fan section 22 drives air along a bypass flow path B in abypass duct defined within a nacelle 15, while the compressor section 24drives air along a core flow path C for compression and communicationinto the combustor section 26 then expansion through the turbine section28. Although depicted as a two-spool turbofan gas turbine engine in thedisclosed non-limiting embodiment, it should be understood that theconcepts described herein are not limited to use with two-spoolturbofans as the teachings may be applied to other types of turbineengines including three-spool architectures.

The exemplary engine 20 generally includes a low speed spool 30 and ahigh speed spool 32 mounted for rotation about an engine centrallongitudinal axis A relative to an engine static structure 36 viaseveral bearing systems 38. It should be understood that various bearingsystems 38 at various locations may alternatively or additionally beprovided, and the location of bearing systems 38 may be varied asappropriate to the application.

The low speed spool 30 generally includes an inner shaft 40 thatinterconnects a fan 42, a first (or low) pressure compressor 44 and afirst (or low) pressure turbine 46. The inner shaft 40 is connected tothe fan 42 through a speed change mechanism, which in exemplary gasturbine engine 20 is illustrated as a geared architecture 48 to drivethe fan 42 at a lower speed than the low speed spool 30. The high speedspool 32 includes an outer shaft 50 that interconnects a second (orhigh) pressure compressor 52 and a second (or high) pressure turbine 54.A combustor 56 is arranged in exemplary gas turbine 20 between the highpressure compressor 52 and the high pressure turbine 54. A mid-turbineframe 57 of the engine static structure 36 is arranged generally betweenthe high pressure turbine 54 and the low pressure turbine 46. Themid-turbine frame 57 further supports bearing systems 38 in the turbinesection 28. The inner shaft 40 and the outer shaft 50 are concentric androtate via bearing systems 38 about the engine central longitudinal axisA which is collinear with their longitudinal axes.

The core airflow is compressed by the low pressure compressor 44 with acompression ratio of at least 2:1 then the high pressure compressor 52,mixed and burned with fuel in the combustor 56, then expanded over thehigh pressure turbine 54 and low pressure turbine 46. The mid-turbineframe 57 includes airfoils 59 which are in the core airflow path C. Theturbines 46, 54 rotationally drive the respective low speed spool 30 andhigh speed spool 32 in response to the expansion. It will be appreciatedthat each of the positions of the fan section 22, compressor section 24,combustor section 26, turbine section 28, and fan drive gear system 48may be varied. For example, gear system 48 may be located aft ofcombustor section 26 or even aft of turbine section 28, and fan section22 may be positioned forward or aft of the location of gear system 48.

The engine 20 in one example is a high-bypass geared aircraft engine. Ina further example, the engine 20 bypass ratio is greater than about six(6), with an example embodiment being greater than about ten (10), thegeared architecture 48 is an epicyclic gear train, such as a planetarygear system or other gear system, with a gear reduction ratio of greaterthan about 2.3 and the low pressure turbine 46 has a pressure ratio thatis greater than about five. In one disclosed embodiment, the engine 20bypass ratio is greater than about ten (10:1), the fan diameter issignificantly larger than that of the low pressure compressor 44, andthe low pressure turbine 46 has a pressure ratio that is greater thanabout five 5:1. Low pressure turbine 46 pressure ratio is pressuremeasured prior to inlet of low pressure turbine 46 as related to thepressure at the outlet of the low pressure turbine 46 prior to anexhaust nozzle. The geared architecture 48 may be an epicycle geartrain, such as a planetary gear system or other gear system, with a gearreduction ratio of greater than about 2.3:1. It should be understood,however, that the above parameters are only exemplary of one embodimentof a geared architecture engine and that the present invention isapplicable to other gas turbine engines including direct driveturbofans.

A significant amount of thrust is provided by the bypass flow B due tothe high bypass ratio. The fan section 22 of the engine 20 is designedfor a particular flight condition—typically cruise at about 0.8 Mach andabout 35,000 feet. The flight condition of 0.8 Mach and 35,000 ft(10,668 meters), with the engine at its best fuel consumption—also knownas “bucket cruise Thrust Specific Fuel Consumption (′TSFC)”—is theindustry standard parameter of 1 bm of fuel being burned divided by 1 bfof thrust the engine produces at that minimum point. “Low fan pressureratio” is the pressure ratio across the fan blade alone, without a FanExit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosedherein according to one non-limiting embodiment is less than about 1.45.“Low corrected fan tip speed” is the actual fan tip speed in ft/secdivided by an industry standard temperature correction of [(Tram °R)/(518.7° R)]^(0.5). The “Low corrected fan tip speed” as disclosedherein according to one non-limiting embodiment is less than about 1150ft/second (350.5 meters/second).

FIG. 2 illustrates the inner shaft 40 driving the geared architecture 48to turn the fan 42 and the low pressure compressor 44 together at thesame rotational speed. The inner shaft 40 is connected with a sun gear60 in the geared architecture 48. The sun gear 60 is surrounded by stargears 62 mounted on star gear bearing assemblies 64 attached to a staticcarrier 66. The static carrier 66 allows the star gears 62 to rotatearound an axis of each star gear 62 but not around and engine axis A.The static carrier 66 is fixed relative to the engine static structure36 on the gas turbine engine 20.

The geared architecture 48 is located radially inward and axiallyaligned with the low pressure compressor 44 to shorten the overalllength of the gas turbine engine 20.

A fan hub 68 is supported by a forward fan bearing 70 and an aft fanbearing 72. The forward fan bearing 70 includes an inner race 74 fixedto the static carrier 66 and an outer race 76 fixed to the fan hub 68.The forward fan bearing 70 supports radial and thrust loads from aforward end of the fan hub 68.

The aft fan bearing 72 includes an inner race 78 attached to the staticcarrier 66, which is connected with the engine static structure 36, andan outer race 80 is attached to a rotating aft support 82. The aft fanbearing 72 supports an aft end of the fan hub 68 and carries radialloads from the fan 42.

A rotatable ring gear 84 turns the fan hub 68 and the low pressurecompressor 44 at the same rotational speed. A rotating compartment wall86 extends from the rotating aft support 82 and is sealed against theengine static structure 36 with an oil seal 88.

Scavenged oil passes through holes 90 extending through the ring gear84, the rotating aft support 82, and the engine static structure 36 todirect oil towards the forward and aft fan bearing 70 and 72 and thegeared architecture 48. A rotating cover 92 aids in retaining anddirecting the oil towards the forward fan bearing 70, the aft fanbearing 72, and the geared architecture 48 and to prevent the need forcarbon seals.

FIG. 3 illustrates another example geared architecture 148. The gearedarchitecture 148 is similar to the geared architecture 48 shown in FIG.2 except where shown in FIG. 3 or described below.

A static carrier 110 includes an oil baffle 100 extending from a forwardend and a cylindrical support 102 for supporting the forward fan bearing70. An oil feed tube 106 supplies oil to the static carrier 110 and therest of geared architecture 148. A multitude of flexible shafts 112extend from the static carrier 110 to support the star gears 62 and therespective star gear bearing assemblies 64. The flexibility of theshafts 112 support torsional loads from the star gears 62 and star gearbearing assemblies 64 and allow the star gears 62 to be isolated fromthe engine static structure 36 such that a static flexible mount is notnecessary to mount the geared architecture 148.

The forward fan bearing 70 in this example includes a roller bearingwith the inner race 74 mounted to the cylindrical support 102 and theouter race 76 rotatably attached to the fan hub 68 through a hub support104. Although a roller bearing is illustrated in this example for theforward fan bearing 70, a ball bearing or a tapered bearing could alsobe utilized.

The aft fan bearing 72, such as a ball bearing, is mounted on an aftside of the geared architecture 148 opposite from the forward bearing70. Although a ball bearing is illustrated in this example for the aftfan bearing 72, a roller bearing or a tapered bearing could also beutilized.

The forward fan bearing 70 and the aft fan bearing 72 straddle thegeared architecture 148 to greatly reduce misalignment imparted on thegeared architecture 148. This eliminates the need for a flexiblecoupling on the geared architecture 148 to combat misalignment forcesacting on the gears.

An inner shaft bearing 114 attached to the engine static structure 36supports a forward end of the inner shaft 40 and carries both radial andthrust loads. Since the fan 42 imparts a forward thrust load and lowpressure turbine 46 imparts an aft thrust load on the inner shaft 40,the opposing loads are generally cancelled out by the aft fan bearing 72and the inner shaft bearing 114 both being attached to the engine staticstructure 36.

The gas turbine engine 20 is designed by attaching the gearedarchitecture 48 or 148 device to the fan hub 68 and the inner shaft 40.The forward fan bearing 70 is positioned forward of the gearedarchitecture 48 or 148 with the first outer race 76 connected to the fanhub 68. The aft fan bearing 72 is positioned aft of the gearedarchitecture 48 or 148. The inner race 74 and the inner race 78 areattached to the static carrier (66 or 110). The ring gear 85 from thegeared architecture 48 or 148 is connected to the fan hub 68.

The preceding description is exemplary rather than limiting in nature.Variations and modifications to the disclosed examples may becomeapparent to those skilled in the art that do not necessarily depart fromthe essence of this disclosure. The scope of legal protection given tothis disclosure can only be determined by studying the following claims.

What is claimed is:
 1. A gas turbine engine comprising: a nacelle, and abypass flow path in a bypass duct within said nacelle of said turbofanengine; a fan section including a fan with fan blades, wherein said fansection drives air along said bypass flow path a fan shaft driving a fanhaving fan blades and said fan rotates about a central longitudinal axisof said turbofan engine; a speed reduction device including an epicyclicgear system; a turbine section connected to the fan section through thespeed reduction device and said turbine section rotates about saidcentral longitudinal axis; a first fan bearing for supporting rotationof the fan hub located axially forward of the speed reduction device; asecond fan bearing for supporting rotation of the fan hub locatedaxially aft of the speed reduction device; and a first outer race of thefirst fan bearing fixed relative to the fan hub.
 2. The gas turbineengine of claim 1, wherein the second fan bearing includes an outer raceand the outer race of the first fan bearing and the outer race of thesecond fan bearing are fixed relative to the fan hub and rotate with thefan hub in the same direction.
 3. The gas turbine engine of claim 2,including an inner race of the first fan bearing fixed from rotationrelative to an engine static structure and an inner race of the secondfan bearing fixed from rotation relative to the engine static structure.4. The gas turbine engine of claim 3, wherein the epicyclic gear systemincludes a sun gear, star gears, a ring gear mechanically attached tothe fan section, and a carrier, the carrier being fixed from rotationrelative to the engine static structure.
 5. The gas turbine engine ofclaim 4, wherein the first fan bearing and the second fan bearinginclude at least one of roller bearings, ball bearings, or taperedbearings and each of the star gears include a star gear bearing.
 6. Thegas turbine engine of claim 5, wherein the carrier includes multipleflexible posts for mounting each of the star gears and the star gearbearing.
 7. The gas turbine engine of claim 3, wherein the first fanbearing is at least partially axially aligned with a fan blade of thefan section.
 8. The gas turbine engine of claim 3, including a carrierfixed from rotation relative to an engine static structure without astatic flexible mount.
 9. The gas turbine engine of claim 3, wherein aninner race of the first fan bearing is fixed from rotation relative to acarrier and the carrier is fixed from rotation relative to an enginestatic structure.
 10. The gas turbine engine of claim 3, including ahigh pressure compressor with a compression ratio of at least 20:1 and afan bypass ratio greater than
 10. 11. The gas turbine engine of claim 3,including a compressor section configured to rotate with the fan sectionand the compressor section includes a five stage low pressure compressorwith a compression ratio of at least 2:1.
 12. The gas turbine engine ofclaim 11, including a rotating compartment wall configured to rotatewith the compressor section and form a seal with an engine staticstructure.
 13. The gas turbine engine of claim 3, wherein the speedreduction device is located radially inward from a first compressor andthe speed reduction device is axially aligned with the first compressor.14. A fan drive gear module comprising a sun gear; a multitude ofintermediate gears surrounding the sun gear; a carrier supporting themultitude of intermediate gears, the carrier is configured to support afan hub with a first fan bearing located on a first side of the carrierand a second fan bearing located on a second opposite side of thecarrier, wherein the carrier is configured to be fixed from rotationrelative to an engine static structure without a static flexible mount;and an outer race of the first fan bearing and an outer race of thesecond fan bearing are fixed relative to the fan hub and rotate with thefan hub in the same direction.
 15. The fan drive gear module of claim14, wherein an inner race of the first fan bearing is fixed fromrotation relative to a carrier and the carrier is fixed from rotationrelative to the engine static structure.
 16. The fan drive gear moduleof claim 15, wherein each of the multitude of intermediate gears includean intermediate gear bearing and the carrier includes multiple flexibleposts for mounting each of the multitude of intermediate gears and theintermediate gear bearing.
 17. The fan drive gear module of claim 14,including a ring gear fixed relative to the fan hub and the first fanbearing and the second fan bearing include at least one of rollerbearings, ball bearings, or tapered bearings.
 18. A method of designinga gas turbine engine comprising: coupling a speed reduction devicebetween a fan hub and a low pressure turbine drive shaft; positioning afirst fan bearing axially forward of the speed reduction device, whereinan outer race of the first fan bearing is fixed relative to the fan huband rotates with the fan hub relative to an engine static structure; andpositioning a second fan bearing axially aft of the speed reductiondevice and an outer race of the second fan bearing is fixed relative tothe fan hub and rotates in the same rotational direction as the outerrace of the first fan bearing.
 19. The method of claim 18, includingpositioning an inner race of the first fan bearing and an inner race ofthe second fan bearing fixed to a carrier and fixed from rotationrelative to the engine static structure.
 20. The method of claim 18,including fixing a ring gear of the speed reduction device relative tothe fan hub to allow the ring gear to rotate with the fan hub and thefirst fan bearing and the second fan bearing include at least one ofroller bearings, ball bearings, or tapered bearings.